JP7431466B2 - Vehicle interior material, method for manufacturing the vehicle interior material, and embossing roll - Google Patents

Description

The present invention relates to a vehicle interior material in which an embossed pattern is formed on a laminated sheet material used mainly for seats and doors, a method for manufacturing the vehicle interior material, and an embossing roll.

BACKGROUND ART Fiber fabrics with embossed patterns formed on the surface are widely known as interior materials for vehicles. For example, Patent Document 1 describes a composite sheet material in which an outer material made of a fiber fabric such as a woven fabric, a knitted fabric, or a non-woven fabric and a cushion layer made of a polyurethane foam material are laminated and integrated to form a deep and clear embossed pattern. A method for producing a skin material for a vehicle seat is described in which embossing is performed between an embossing roll and a heat roll that are both heated to a temperature in the range of 100°C to 250°C.

Further, Patent Document 2 includes a base material and a recess provided on the surface of the base material, the depth direction of which corresponds to the thickness direction of the base material, and the recess is an inner surface of the recess. A decorative sheet is described, which includes a first uneven pattern in a first region thereof, and includes a second uneven pattern different from the first uneven pattern in a second region of the inner surface different from the first region. According to this decorative sheet, light can be reflected in different states in the first region and the second region. It is stated that when the surface of a decorative sheet is viewed from two or more different directions, a viewer of the decorative sheet can be made to believe that the same recessed portion is a different recessed portion.

Japanese Patent Application Publication No. 2007-276285 International Publication WO2019/159613 Publication

Vehicle interior materials such as seats and doors are required to have an unprecedented design quality, and embossed patterns, which are a type of decoration, are required to have an unprecedented form and more advantageous processing methods. For example, in the conventional technology described in Patent Document 1, when a composite sheet material in which a outer material and a cushion layer are laminated and integrated is embossed using an embossing roll with a uniform height of the convex portions, the cushion layer is The degree of shaping is also uniform, and the concave portions form an uneven pattern of uniform depth on the composite sheet material.

By the way, even if an embossing roll with uneven heights of convex parts is used to form an embossed pattern with different depths of concave parts on a composite sheet material, the height of the convex parts of the embossing roll is relatively low. Since the pressure is weak in the convex portions, it is not easy to form an embossed pattern with different depths in the concave portions, resulting in poor design.

Therefore, in order to sufficiently form the uneven pattern with uneven depth, we used an embossing roll with a complex uneven shape to perform embossing while increasing the pressure on the convex part of the embossing roll and lengthening the forming time. When this is applied, there is a problem that the concave portions of the composite sheet material harden in the convex portions with a large area among the convex portions of the embossing roll, which reduces the elongation of the composite sheet material and causes wrinkles during sewing.

In addition, such embossing molds, that is, embossing rolls, need to be provided with convex portions of different heights, and complex convex shapes such as steps and slopes, which may increase the manufacturing cost of the embossing rolls. there were.

On the other hand, if an elastic part such as rubber is provided on the surface of the embossing mold that pairs with the embossing roll, that is, the backup roll, it is necessary to press the uneven shape of the embossing roll even more strongly against the decorative sheet. If the surface layer is a fibrous sheet material, even if the fibrous sheet material is strongly compressed, the elastic rubber roll cannot be heated, so there is a risk that the second sheet with cushioning properties, that is, the soft urethane foam, will not be able to be given a sufficient shape. was there.

The present invention has been made in view of this technical background, and an object of the present invention is to provide a vehicle interior material having an unprecedented design quality. Another object of the present invention is to provide a method for producing a vehicle interior material with a more advantageous processing method, and to provide an embossing roll for producing the vehicle interior material, which has an embossed pattern that has not been seen before.

In order to achieve the above object, the present invention provides the following means.

[ 1 ] A method for manufacturing a vehicle interior material in which an embossed pattern is formed on a composite sheet material in which a fiber fabric layer and a cushion layer are laminated and integrated,
A step of supplying the composite sheet material between an embossing roll whose surface has a plurality of embossing portions protruding from it and a backup roll whose surface is made of metal;
heating and pressing the composite sheet material with the fiber fabric layer side facing the embossing roll,
The embossing portion has the same height from the base surface of the embossing roll,
having a recess in a part of the area including the end of the top surface of the embossing part;
There is no uneven pattern on the top surface except for the above region,
The embossed pattern forms a bottom portion, a middle portion, and a top portion of the composite sheet material having different thicknesses,
There is no uneven pattern on the bottom,
The intermediate portion is approximately flat and/or approximately sloped, and an uneven pattern is formed in the intermediate portion,
The uneven pattern of the intermediate part is different from the pattern of the top part and/or the bottom part,
The total area of the convex portions of the uneven pattern in the intermediate portion is 25% to 75% of the total area of the intermediate portion,
A vehicle interior material, characterized in that the depth of the concave portions of the concavo-convex pattern is more than 1 mm, and the distance between adjacent concave portions of the concave-convex pattern is 0.1 mm or more in any one of vertical, horizontal, and diagonal directions. manufacturing method.

[ 2 ] The area of the recess in a part of the region including the end of the top surface of the embossing portion is 25% to 75% of the area of the region,
The depth of the recess is more than 1 mm, and the distance between adjacent recesses is 0.1 mm or more in any of the vertical, horizontal, and diagonal directions,
2. The method for manufacturing a vehicle interior material according to item 1, wherein the embossing portion has a height of 1 mm or more.

In the invention [ 1 ], it is possible to form an embossed pattern in a more complicated and unprecedented form, and it is possible to provide a more advantageous method for manufacturing vehicle interior materials. That is, the bottom, middle, and top parts can be formed more reliably, and the uneven pattern on the surface side of the middle part can be provided with an even more outstanding design. Further, it is possible to provide a method for manufacturing a vehicle interior material that does not cause the possibility of partially hardening the bottom of the embossed pattern of the composite sheet material and can provide a sufficient shape to the cushion layer.

In the invention of [ 2 ], the bottom, middle, and top parts of the composite sheet material having different thicknesses can be formed on the surface side, and the middle part is formed as the middle part, which is a substantially flat surface and/or a substantially sloped surface. In addition, it is possible to provide a method for manufacturing a vehicle interior material in which the uneven pattern formed in the intermediate portion is dispersed and there is no fear of hardening the bottom portion of the embossed pattern of the composite sheet material. There is no need to provide embossed portions with different heights on the surface of the embossing roll, or to provide complex convex shapes such as steps or slopes on the embossed portion, so there is no fear that the manufacturing cost of the embossing roll will become higher. stomach.

FIG. 1 is a perspective view of a vehicle interior material according to a first embodiment of the present invention. FIG. 3 is a perspective view of a vehicle interior material according to a second embodiment of the present invention. FIG. 1 is an explanatory diagram (plan view) of vehicle interior materials according to first and second embodiments of the present invention. FIG. 2 is a sectional view of a composite sheet material used in the present invention. FIG. 2 is a partially sectional view showing an enlarged embossing portion of the embossing roll according to the first embodiment of the present invention. FIG. 1 is an explanatory diagram of a method for manufacturing a vehicle interior material according to a first embodiment of the present invention. It is a partial cross-sectional view which expands and shows the embossing part of the embossing roll based on 2nd embodiment of this invention. It is an explanatory view of the manufacturing method of the interior material for vehicles concerning the second embodiment of the present invention. It is a cross-sectional photograph of a vehicle interior material according to a second embodiment of the present invention. It is a partial sectional view which expands and shows the embossing part of the conventional embossing roll. FIG. 2 is an explanatory diagram showing an example of a roll embossing device used in the present invention.

Next, an embodiment of a vehicle interior material according to the present invention will be described with reference to FIGS. 1 to 4. FIG. 1 is a perspective view of a vehicle interior material according to a first embodiment, and FIG. 2 is a perspective view of a vehicle interior material according to a second embodiment.

As shown in FIGS. 1 and 2, a vehicle interior material 1 according to the present invention is a vehicle interior material in which an embossed pattern is formed on a composite sheet material 4 in which a fiber fabric layer 2 and a cushion layer 3 are laminated and integrated. The embossed pattern is formed on the fiber fabric layer 2 side on the front side, and the composite sheet material 4 has a bottom part 5, a middle part 6, and a top part 7 with different thicknesses on the front side, and the middle part 6 is formed on the front side. It is substantially flat and/or substantially sloped, has an uneven pattern 9 on the front side of the intermediate part 6, and has no uneven pattern on the back side, and the uneven pattern 9 is different from the pattern on the top part 7 and/or the bottom part 5. The total area of the convex portions of the concavo-convex pattern 9 is 25% to 75% of the total area of the intermediate portion 6 of the composite sheet material 4, and the concave portions of the concave-convex pattern 9 of the intermediate portion 6 include independent concave portions. Features.

The fiber fabric layer 2 of the present invention is not particularly limited, but includes, for example, woven fabrics, knitted fabrics, and nonwoven fabrics. In addition, examples of the fibers constituting the fiber fabric layer 2 include synthetic fibers such as polyester fibers, polyamide fibers, and polyacrylonitrile fibers, cotton fibers, and rayon fibers. Further, these may be combined as appropriate.

As the cushion layer 3 of the present invention, a flexible urethane foam is preferable because the density, hardness, and thickness can be selected within a range that provides good cushioning properties. Specifically, the density is preferably in the range of 15Kg/m ³ to 45Kg/m ³ , the hardness is preferably in the range of 60N to 180N/cm ² , and the thickness is preferably in the range of 1mm to 10mm. Further, a material in which a knitted fabric is laminated on the back side of a soft urethane foam is preferable because it has excellent process passability in the manufacturing process of the vehicle interior material 1 and improves workability when cutting the vehicle interior material 1.

As shown in FIG. 4, the composite sheet material 4 is made by laminating and integrating a fiber fabric layer 2 and a cushion layer 3. The method of laminating and integrating the fiber fabric layer 2 and the cushion layer 3 is not particularly limited, but examples include a method using an adhesive and a method using a frame lamination method. Among these, the frame lamination method is more preferable from the viewpoint of strength against delamination, productivity, etc., and can further improve the strength of the integration of the fiber fabric layer 2 and the cushion layer 3 in a state where the embossed pattern is formed.

The embossed pattern of the present invention is formed on the fiber fabric layer 2 side of the composite sheet material 4, and the composite sheet material 4 has a bottom portion 5, a middle portion 6, and a top portion 7 having different thicknesses on the surface side. More specifically, when the composite sheet material 4 is viewed as a whole, the embossed pattern has at least three different heights, ie, a bottom part 5, a middle part 6, and a top part 7, in descending order of height. This becomes the design surface of material 1 (Figures 1 and 2). Although not shown in FIGS. 1 and 2, the intermediate portion 6 has the uneven pattern 9, so that the vehicle interior material 1 can have a more complex and excellent design than ever before.

As shown in FIGS. 1 and 2, in the present invention, when the composite sheet material 4 is viewed as a whole, the intermediate portion 6 of the embossed pattern is substantially flat and/or substantially sloped. Since the intermediate portion 6 is substantially flat and/or substantially sloped, the embossed pattern has more variation, so the vehicle interior material 1 can have an excellent design. The first embodiment of the present invention is a substantially flat surface, and the second embodiment is a substantially sloped surface. Note that FIG. 9 is a cross-sectional photograph of a vehicle interior material according to the second embodiment of the present invention, which has an uneven pattern in the intermediate portion 6.

The intermediate part 6 of the present invention has a concavo-convex pattern 9 on the front side of the intermediate part 6, but there is no concave-convex pattern on the back side, and the presence or absence of the concave-convex pattern on the bottom part 5 and the top part 7 is not particularly limited. The uneven pattern 9 is different from the uneven pattern on the top part 7 and/or the bottom part 5. Note that if there is no uneven pattern on the bottom part 5 and the top part 7, it is naturally different from the uneven pattern 9 on the intermediate part 6. FIG. 3 shows examples of a border pattern as the uneven pattern (bottom part) 8, a rectangular pattern and a triangular pattern as the uneven pattern (middle part) 9, and a border pattern as the uneven pattern (top part) 10, as well as the bottom part 5, the middle part 6, An example in which the top portion 7 does not have a concavo-convex pattern is shown. Note that the uneven pattern (intermediate portion) 9 is smaller in depth and size than the embossed pattern of the composite sheet material 4.

In the present invention, the total area of the convex portions of the uneven pattern 9 of the intermediate portion 6 is 25% to 75% of the total area of the intermediate portion 6 of the composite sheet material 4. By setting the total area of the convex parts of the uneven pattern 9 of the intermediate part 6 within this range, the height between the bottom part 5 and the top part 7 can be more reliably recognized as the intermediate part 6, and the uneven pattern 9 of the intermediate part 6 can be more clearly recognized. The vehicle interior material 1 can have an even more outstanding design. In addition, the total area of the intermediate part 6 is the total area of the continuous intermediate part 6 shaped by one embossing part of the embossing roll 11. Further, the concave portions of the concavo-convex pattern 9 of the intermediate portion 6 include independent concave portions. On the other hand, if the recesses are not independent but are all connected, it is difficult to say that it is the intermediate part 6. As shown in FIG. 3, the total area of the convex parts of the rectangular uneven pattern (middle part) 9 and the triangular uneven pattern (intermediate part) 9 are each shaped by one corresponding embossing part of the composite sheet material 4. It is 25% to 75% of the total area of the continuous intermediate portion 6.

Next, a method for manufacturing a vehicle interior material according to the present invention will be described with reference to FIGS. 5 to 11.

The method for manufacturing a vehicle interior material 1 according to the present invention is a method for manufacturing a vehicle interior material in which an embossed pattern is formed on a composite sheet material 4 in which a fiber fabric layer 2 and a cushion layer 3 are laminated and integrated. A step of supplying the composite sheet material 4 between an embossing roll 11 having a protruding embossing portion 13 on the surface and a backup roll 12 whose surface is made of metal, and a step of supplying the composite sheet material 4 between the embossing roll 11 having a protruding embossing part 13 on the surface, and the step of supplying the composite sheet material 4 with the fiber fabric layer 2 side facing the embossing roll 11 side. and heating and pressing the sheet material 4, the embossing portion 13 has the same height H from the base surface 14 of the embossing roll 11, and the embossed pattern is formed on the bottom portion of the composite sheet material 4 having different thicknesses. 5, an intermediate portion 6, and a top portion 7, the intermediate portion 6 is approximately flat and/or approximately sloped, and an uneven pattern 9 is formed on the intermediate portion 6, and the uneven pattern 9 of the intermediate portion 6 is formed on the top portion 7 and/or the intermediate portion 6. Or, unlike the pattern on the bottom part 5, the total area of the convex parts of the uneven pattern 9 of the intermediate part 6 is 25% to 75% of the total area of the intermediate part 6, and the depth Ha of the concave parts 16 of the uneven pattern 9 is It is characterized in that it exceeds 1 mm, and the distance between adjacent recesses 16 is 0.1 mm or more in any one of the vertical, horizontal, and diagonal directions.

The vehicle interior material 1 according to the present invention can be manufactured using the embossing roll 11 having the embossing portion 13 shown in FIG. 5 or 7, and by a roll embossing device shown in FIG. 11(1) or FIG. 11(2), for example. . In both FIGS. 11 and 12, the embossing portion 13 protruding from the surface of the embossing roll 11 is not shown.

In order to form an embossed pattern on the composite sheet material 4 using a roll embossing device, between an embossing roll 11 that is rotatably provided and a backup roll 12 that is rotatably provided opposite the embossing roll 11. , the composite sheet material 4 may be supplied and passed through with the fiber fabric layer 2 facing the embossing roll 11. The supplied composite sheet material 4 is heated and pressed between an embossing roll 11 and a backup roll 12.

The embossing roll 11 and the backup roll 12 have metal surfaces and are preferably made of carbon steel, preferably S25C or S45C, since they have good thermal conductivity.

Although not shown in FIG. 11(1) or FIG. 11(2), the embossing roll 11 and the backup roll 12 are each equipped with a heating means. In the heating and pressing step, the embossing roll 11 preferably has a temperature range of 160°C to 210°C, and the backup roll 12 preferably has a temperature range of 160°C to 235°C. If the temperature of the embossing roll 11 is lower than 160°C, the embossed pattern may be weakly formed, and if the temperature of the embossing roll 11 is higher than 210°C, sharp recesses may occur in the fiber fabric layer 2, so it is preferable. do not have. Furthermore, if the temperature of the backup roll 12 is lower than 160°C, it may be difficult to form the cushion layer 3 sufficiently, and if the temperature of the backup roll 12 is higher than 235°C, the back surface of the cushion layer 3 may be difficult to form. This is not preferable because the laminated knitted fabric may melt and be fused to the backup roll 12.

On the surface of the embossing roll 11, an embossing part 13 is provided protrudingly as shown in FIG. 5 and/or FIG. 7, and the height H of the embossing part 13 from the base surface 14 of the embossing roll 11 is the same. be. Note that a plurality of embossing portions 13 may be provided as needed. Further, the top surface 15 of the embossing portion 13 has a region A in which a recess 16 having a depth Ha smaller than the height H is provided. A plurality of regions A may be provided in one embossing portion 13, and the area of each region A may be different for each region A. FIG. 5 shows an example of the embossed part 13 in which the area A is provided at one location and the embossed part 13 in which the area A is provided at two locations.

FIG. 6 is an explanatory diagram of a method for manufacturing the vehicle interior material 1 according to the first embodiment, in which heating and pressing is performed using the embossing roll 11 having the embossing portion 13 shown in FIG. FIG. 6 shows (1) before embossing, (2) during embossing, and (3) after embossing in order. (1) Before embossing, the composite sheet material 4 and the embossing roll 11 are separated, (2) During embossing, the composite sheet material 4 is heated and pressed by the embossing roll 11, (3) After embossing, the composite sheet material 4 is shown to have a bottom portion 5 of different thickness, a substantially flat intermediate portion 6, and a top portion 7.

As shown in FIG. 6, a bottom portion 5, a middle portion 6, and a top portion 7 having different thicknesses are formed in the composite sheet material 4. Specifically, the middle part 6 corresponds to the surface of the composite sheet material 4 heated and pressed by the area A of the embossing part 13, and the bottom part 5 other than the area A of the embossing part 13 corresponds to the base surface 14 of the embossing roll 11. A top portion 7 is formed, and a concavo-convex pattern 9 is formed on the intermediate portion 6, although not shown in FIG. In the intermediate part 6, when the embossing roll 11 heats and presses the area A, the area in contact with the composite sheet material 4 is considered to be relatively small and the pressure is weak because of the concave part 16 in the region A. Even though the height H from the base surface 14 is the same, it is possible to form a substantially flat intermediate portion 6 and to form an uneven pattern 9 on the intermediate portion 6.

FIG. 8 is an explanatory diagram of a method for manufacturing a vehicle interior material 1 according to the second embodiment, in which heating and pressing is performed using an embossing roll 11 having an embossing portion 13 shown in FIG. 7. In the embossed part 13 shown in FIG. 7, the distance between adjacent recesses of the recesses 16 in area A of the embossed part 13 is gradually increased compared to the embossed part 13 shown in FIG. FIG. 8 shows (1) before embossing, (2) during embossing, and (3) after embossing in order. (1) Before embossing, the composite sheet material 4 and the embossing roll 11 are separated, (2) During embossing, the composite sheet material 4 is heated and pressed by the embossing roll 11, (3) After embossing, the composite sheet material 4 is shown to have a bottom portion 5 of different thickness, a substantially sloped intermediate portion 6, and a top portion 7.

As shown in FIG. 8, the composite sheet material 4 has a bottom portion 5, a middle portion 6, and a top portion 7 having different thicknesses. Specifically, the middle part 6 corresponds to the surface of the composite sheet material 4 heated and pressed by the area A of the embossing part 13, and the bottom part 5 other than the area A of the embossing part 13 corresponds to the base surface 14 of the embossing roll 11. A top portion 7 is formed, and a concavo-convex pattern 9 is formed on the intermediate portion 6, although not shown in FIG. In the intermediate part 6, when the embossing roll 11 heats and presses the area A, the area in contact with the composite sheet material 4 is considered to be relatively small and the pressure is weak because of the concave part 16 in the region A. Even though the height H from the base surface 14 is the same, it is possible to form a substantially sloped intermediate portion 6 and to form an uneven pattern 9.

As the embossing roll 11, the embossing part 13 shown in FIG. 5 and that shown in FIG. 7 may be mixed. In this case, it is possible to manufacture a vehicle interior material 1 having a design in which both the substantially flat intermediate portion 6 and the substantially sloped intermediate portion 6 are mixed.

Further, the pressing force between the embossing roll 11 and the backup roll 12 is preferably in the range of 2 to 60 kg/cm ² , and the passing speed of the composite sheet material 4 is preferably in the range of 0.1 to 5 m/min. This range is preferable because the bottom portion 5, middle portion 6, and top portion 7 of the composite sheet material 4 having different thicknesses can be formed more stably.

According to the manufacturing method of the vehicle interior material 1 according to the present invention, the uneven pattern 9 of the intermediate part 6 is different from the uneven pattern of the top part 7 and/or the bottom part 5, and the uneven pattern 9 of the intermediate part 6 is different from the uneven pattern 9 of the intermediate part 6. The total area is 25% to 75% of the total area of the intermediate portion 6, the depth Ha of the recesses 16 of the uneven pattern 9 exceeds 1 mm, and the distance between adjacent recesses 16 is either vertical, horizontal, or diagonal. Since it is 0.1 mm or more in the direction of Can be given a design quality. Conversely, even if the total area of the convex parts of the uneven pattern 9 of the intermediate part 6 is 25% to 75% of the total area of the intermediate part 6, the depth Ha of the concave parts of the uneven pattern 9 exceeds 1 mm, and Unless the distance between the adjacent recesses satisfies the condition of 0.1 mm or more in any one of the vertical, horizontal, and diagonal directions, there is a possibility that a clear intermediate portion 6 will not be formed. Even if the depth Ha of the concave portions of the uneven pattern 9 exceeds 1 mm and the distance between the adjacent concave portions is 0.1 mm or more in any of the vertical, horizontal, and diagonal directions, the total area of the intermediate portion 6 If it is less than 25%, it will approximate the height of the top part 7, and if it exceeds 75% of the total area of the intermediate part 6, it will approximate the height of the bottom part 5, so there is a risk that it will not be possible to form a clear intermediate part 6. . In addition, the total area of the intermediate part 6 is the total area of the continuous intermediate part 6 shaped by one embossing part of the embossing roll 11.

Next, the embossing roll will be explained. As a conventional embossing roll, there is one having an embossing part shown in FIG. 10 (1) or FIG. 10 (2), for example. When the composite sheet material 4 is heated and pressed by the embossing part shown in FIG. Although an embossed pattern can be formed on the surface of the sheet material 4, an uneven pattern cannot be easily formed in the intermediate portion of the stepped surface 18, even in the substantially flat intermediate portion of the present invention. Furthermore, when the composite sheet material 4 is heated and pressed by the embossing section shown in FIG. 10(2), an embossed pattern can be formed on the surface of the composite sheet material 4. However, it is not possible to easily form an uneven pattern in the intermediate portion. In other words, even if an uneven pattern is formed on the step surface 18 of the embossing part in FIG. 10 (1) or the slope 20 of the embossing part in FIG. A clear uneven pattern cannot be formed on the surface of the sheet material 4. On the other hand, if the pressure is too strong to obtain a sufficient embossed pattern, the bottom of the embossed pattern tends to harden, and if you try to suppress this hardening, it becomes difficult to obtain a sufficient embossed pattern. Further, the embossing roll having the embossing portion shown in FIG. 10(1) or FIG. 10(2) has a problem in that the degree of difficulty in cutting becomes high and the manufacturing cost of the embossing roll becomes high.

On the other hand, as an embossing roll according to the present invention, for example, an embossing roll 11 having an embossing part 13 shown in FIG. 5 or FIG. This is an embossing roll for forming a pattern, and a plurality of embossing parts 13 are provided protrudingly on the surface of the embossing roll 11, and a recess 16 is provided in a part A of the top surface 15 of the embossing part 13. 16 is 25% to 75% of the area of region A, the depth Ha of the recess 16 is more than 1 mm, and the distance between adjacent recesses 16 is 0.1 mm in any of the vertical, horizontal, and diagonal directions. As described above, the height H of the embossed portions 13 is 1 mm or more, and the heights H of the embossed portions 13 are the same.

By adopting such a configuration, the bottom portion 5, middle portion 6, and top portion 7 having different thicknesses of the composite sheet material 4 can be formed on the front side, and the middle portion can be formed with a substantially flat surface and/or a substantially sloped surface. It is possible to provide an embossing roll 11 which can form a certain intermediate part 6 and which does not cause the possibility of hardening the bottom part 5 of the embossed pattern of the composite sheet material 4. In this way, the embossing roll 11 of the present invention does not require the embossing portions 13 having different heights on the surface or having complicated shapes such as steps or slopes on the embossing portion 13, so the manufacturing cost of the embossing roll 11 is reduced. There is no fear that it will be expensive.

In the embossing roll 11 of the present invention, a plurality of areas A may be provided in one embossing part 13, and if the area is in the range of 25% to 75% of the area of the area A, for example, 30 %, 50%, and 70%, intermediate portions 6 having different heights can be formed in the composite sheet 4. Furthermore, by setting the area of the recessed portion 16 to gradually increase from 30% to 70% within one area A, it is possible to more reliably make the intermediate portion 6 a substantially sloped surface instead of a substantially flat surface. be able to.

By the way, in the embossing roll 11 of the present invention, even if the area of the recesses 16 is 25% to 75% of the area of the area A, the depth Ha of the recesses 16 exceeds 1 mm, and the distance between adjacent recesses 16 is If the distance does not satisfy the condition of 0.1 mm or more in any of the vertical, horizontal, and diagonal directions, it will not be possible to provide an excellent design that makes the uneven pattern of the intermediate portion 6 of the composite sheet material 4 even more prominent. Furthermore, even if the depth Ha of the recesses 16 exceeds 1 mm and the distance between adjacent recesses 16 is 0.1 mm or more in any of the vertical, horizontal, or diagonal directions, it is less than 25% of the area of region A. In this case, the height of the intermediate part 6 will approximate the height of the top part 7, and if it exceeds 75% of the area of area A, the height of the intermediate part 6 will approximate the height of the bottom part 5. The concavo-convex pattern of the intermediate portion 6 of the composite sheet material 4 cannot provide an even more outstanding design. The depth Ha of the recess 16 in the region A is preferably in the range of 1.0 mm to 2.0 mm, which is equal to or greater than the thickness of the fiber fabric layer 2.

The height H of the embossing part 13 of the embossing roll 11 of the present invention is 1 mm or more, and the height H of the embossing part 13 is the same. By setting it within this range, there is no need to provide the embossing portions 13 with different heights on the surface of the embossing roll 11 or complicated convex shapes such as steps and slopes on the embossing portion 13, so the manufacturing cost of the embossing roll 11 is reduced. is not more expensive.

Furthermore, during heating and pressing by the embossing roll 11, it is thought that the pressure is relatively weak in the area A of the embossing part 13, and the embossing part 13 has the same height H from the base surface 14 of the embossing roll 11. Nevertheless, not only can the intermediate portion 6 be formed, but also the uneven pattern 9 can be formed in the intermediate portion 6, and the uneven pattern 9 can be provided with an even more outstanding design.

By the way, if the height H of the embossed part 13 is less than 1 mm, it is too small compared to the thickness of the composite sheet material 4, so that a sufficient intermediate part 6 cannot be formed. Furthermore, since there is a possibility that the base surface 14 comes into contact with the top portion 7 during heating and pressing, this may have an adverse effect such as hardening or discoloration of the fiber fabric layer 2. Note that the height H of the embossing portion 13 is preferably in the range of 3.0 mm to 12.0 mm.

Next, specific examples of the present invention will be described, but the present invention is not particularly limited to these examples.

<Materials used, etc.>
Fiber fabric layer: woven fabric (thickness 1.0mm)
Cushion layer: Soft urethane foam (density 20Kg/m ³ , hardness 98.1N/cm ² , thickness 5mm, manufactured by INOAC Corporation, product name EL67)
Back fabric of cushion layer: knitted fabric (polyester fiber jersey, basis weight 40g/m ² )
Composite sheet material: A cushion layer is laminated onto the above fiber fabric layer using the frame lamination method (total thickness 7.0 mm)
Emboss roll embossing part Height of embossing part H: 10.0mm
Ha of the recess in area A of the embossing part: 1.5 mm
Area of recess in area A/Percentage of area in area A: 50%

<Example 1>
Using a roll embossing device as shown in FIG. 11(1) or (2), an embossed pattern was formed on the fiber fabric layer side of the above-mentioned composite sheet material prepared in advance. That is, the fiber fabric layer surface of the composite sheet material was placed on the embossing roll side, and the passing speed of the composite sheet material was set to 2 m/min, and as shown in FIG. Using an embossing roll with an embossing part in which the distance between the recesses is uniform, the composite sheet material was rolled at 50 kg/cm between the embossing roll (surface temperature: 210°C) and the backup roll (surface temperature: 230°C). It was heated and pressed at a pressure of ² . For vehicles, the embossed pattern is formed on the surface side of the composite sheet material, with a bottom part of the composite sheet material having different thicknesses, a substantially flat middle part, and a top part, and an uneven pattern is formed on the fiber fabric layer in the middle part. Obtained interior materials. The percentage of the total area of the convex portions of the uneven pattern in the area of the continuous intermediate portion was 50%. The thicknesses of the top, middle (substantially flat), and bottom parts of the embossed pattern were 7 mm, 2.5 mm, and 1.2 mm, respectively. The formation evaluation of the middle part was "◎", and the evaluation of the clarity of the uneven pattern in the middle part was "◎".

<Example 2>
In Example 1, a vehicle interior was produced in the same manner as in Example 1, except that an embossing roll having a ratio of the area of the recess in region A/the area of region A was 30%, and the surface temperature of the embossing roll was set to 190°C. I got the material. The bottom, middle (approximately flat) and top parts of the composite sheet material having different thicknesses are formed on the front side, and the fiber fabric layer in the middle part is formed with an uneven pattern, and the unevenness occupies the area of the continuous middle part. The percentage of the total area of the raised portions of the pattern was 30%. The thicknesses of the top, middle (substantially flat), and bottom parts of the embossed pattern were 7 mm, 3.8 mm, and 1.3 mm, respectively. The evaluation of the formation of the middle part was "○", and the evaluation of the clarity of the uneven pattern in the middle part was "◎".

<Example 3>
In Example 2, an interior material for a vehicle was obtained in the same manner as in Example 2, except that an embossing roll having a ratio of the area of the recess in region A/the area of region A was 70%. The bottom, middle (approximately flat) and top parts of the composite sheet material having different thicknesses are formed on the front side, and the fiber fabric layer in the middle part is formed with an uneven pattern, and the unevenness occupies the area of the continuous middle part. The percentage of the total area of the raised portions of the pattern was 70%. The thicknesses of the top, middle (substantially flat), and bottom parts of the embossed pattern were 7 mm, 2.0 mm, and 1.3 mm, respectively. The evaluation of the formation of the middle part was "○", and the evaluation of the clarity of the uneven pattern in the middle part was "◎".

<Example 4>
In Example 2, the area of the recess in region A/the percentage of the area of region A is 50%, but as shown in FIG. 8, the distance between adjacent recesses in region A of the embossing portion gradually increases. A vehicle interior material was obtained in the same manner as in Example 2, except that an embossing roll having embossed portions that were spaced apart, that is, the interval between the concave portions in region A was gradated, was used. The bottom, middle (approximately sloped), and top parts of the composite sheet material have different thicknesses and are formed on the front side, and the fiber fabric layer in the middle part is formed with an uneven pattern, and the unevenness occupies the area of the continuous middle part. The percentage of the total area of the convex portions of the pattern was 50%. The thickness of the top and bottom of the embossed pattern is 7 mm and 1.3 mm, respectively, and the thickness of the middle part is 2.5 mm at the center, 3.8 mm near the top, and 3.8 mm near the bottom. The thickness was 2.0 mm, and the middle part of the slope was formed. The evaluation of the formation of the middle part was "O", and the evaluation of the clarity of the uneven pattern in the middle part was "O".

<Comparative example 1>
In Example 2, an interior material for a vehicle was obtained in the same manner as in Example 2, except that an embossing roll having a ratio of the area of the recess in region A/the area of region A was 80%. A bottom part and a top part of the composite sheet material having different thicknesses are formed on the front side, and although an uneven pattern was formed on the fiber fabric layer between the bottom part and the top part, the thickness was only 1.5 mm, and the bottom part and the top part were formed with an uneven pattern. It was difficult to distinguish and was not recognized as the middle part of the embossed pattern. The percentage of the convex portions of the uneven pattern in the intermediate portion of the continuous intermediate portion was 80%. The thicknesses of the top, middle, and bottom of the embossed pattern were 6.5 mm, 1.5 mm, and 1.3 mm, respectively. The evaluation of the formation of the middle part was "x", and the evaluation of the clarity of the uneven pattern in the middle part was "◎".

<Comparative example 2>
In Example 2, an interior material for a vehicle was obtained in the same manner as in Example 2, except that an embossing roll having a ratio of the area of the recess in region A/the area of region A was 10%. A bottom and top part with different thicknesses of the composite sheet material were formed on the front side, and although an uneven pattern was formed on the fiber fabric layer between the bottom part and the top part, the thickness was 5.5 mm and it was distinguishable from the top part. It was difficult to recognize that it was the middle part of the embossed pattern. The percentage of the total area of the convex portions of the concavo-convex pattern to the area of the continuous intermediate portion was 10%. The thicknesses of the top and bottom of the embossed pattern were 7 mm and 1.3 mm, respectively. The height between the top and the bottom was 5.5 mm, and there was almost no difference in height from the top, so it could not be recognized as an intermediate part, and the evaluation of the formation of the intermediate part was "x". Moreover, the clarity evaluation of the uneven pattern in the middle part was "◎".

<Comparative example 3>
In Example 2, the area of the recess in area A/the percentage of the area of area A is 50%, but the height of area A is 0.5 mm lower than the height H of the embossing part, that is, the top of area A is 50%. A vehicle interior material was obtained in the same manner as in Example 2, except that an embossing roll having an embossing portion with a surface height of 9.5 mm was used. The percentage of the total area of the convex portions of the uneven pattern in the area of the continuous intermediate portion was 50%. The thicknesses of the top, middle, and bottom of the embossed pattern were 7 mm, 4.5 mm, and 1.3 mm, respectively. The formation evaluation of the middle part was "Good", but because the height of region A of the embossed part was 0.5 mm lower, the clarity evaluation of the uneven pattern in the middle part was "△".

In each of the vehicle interior materials of Examples 1 to 3, a substantially flat intermediate portion was formed, and the evaluation of the formation of the intermediate portion was clear or sufficiently visible, and the uneven pattern applied to the intermediate portion was also clear. It had an excellent design. Furthermore, in the vehicle interior material of Example 4, a slope is formed approximately in the middle of the slope, that is, from the bottom to the top of the embossed pattern, and the slope has a concavo-convex pattern that is sufficiently visible. It was of excellent quality.

On the other hand, in Comparative Examples 1 and 2, no intermediate part was observed between the top and bottom of the embossed pattern, and in Comparative Example 3, although the intermediate part was visible, the uneven pattern in the intermediate part was unclear and poor in design. It was something.

<Evaluation of formation of middle part>
The formation of the middle part of the embossed pattern of vehicle interior material was evaluated. That is, the vehicle interior material was placed on a desk with the surface (fiber fabric layer) facing up, visually observed from an angle of 45 degrees to 60 degrees, and evaluated using the following criteria. It can be said that it is a vehicle interior material with an excellent design because a middle part is formed and the difference between the top and bottom parts is clear or sufficiently visible. A score of "〇" or higher was considered a pass.
(Judgment criteria)
"◎": The middle part of the embossed pattern is clear.
“〇”: The middle part of the embossed pattern is sufficiently visible.
"Δ": The middle part of the embossed pattern is unclear.
"×": Not recognized as the middle part of the embossed pattern.

<Evaluation of clarity of uneven pattern in the middle part>
The clarity of the uneven pattern on the surface (fiber fabric layer) of the middle part of the embossed pattern was evaluated. That is, the vehicle interior material was placed on a desk with the surface (fiber fabric layer) facing up, visually observed from an angle of 45 degrees to 60 degrees, and evaluated using the following criteria. A score of "〇" or higher was considered a pass.
(Judgment criteria)
"◎": The uneven pattern in the middle part is clear.
“〇”: The uneven pattern in the middle part is sufficiently visible.
"Δ": The uneven pattern in the middle part is unclear.
"x": No uneven pattern in the middle part.

The vehicle interior material, the method for manufacturing the vehicle interior material, and the embossing roll according to the present invention are suitable mainly for seats, doors, etc., and as an embossing roll for the manufacturing method for the seat and door. It is.

1... Vehicle interior material 2... Fiber fabric layer 3... Cushion layer 4... Composite sheet material 5... (embossed pattern) bottom part 6... (embossed pattern) middle part 7...・(Embossed pattern) Top part 8... Uneven pattern (Bottom part)
9... Uneven pattern (middle part)
10... Uneven pattern (top)
11... Embossing roll 12... Backup roll 13... Embossed part 14... Base surface 15... Top surface 16... Recessed part 17... Conventional embossing roll 18... Step surface 19... Conventional embossing roll 20... Slope A... Area H... Height of embossing part Ha... Depth of recessed part

Claims (2)

A method for manufacturing a vehicle interior material in which an embossed pattern is formed on a composite sheet material in which a fiber fabric layer and a cushion layer are laminated and integrated, the method comprising:
A step of supplying the composite sheet material between an embossing roll whose surface has a plurality of embossing portions protruding from it and a backup roll whose surface is made of metal;
heating and pressing the composite sheet material with the fiber fabric layer side facing the embossing roll,
The embossing portion has the same height from the base surface of the embossing roll,
having a recess in a part of the area including the end of the top surface of the embossing part;
There is no uneven pattern on the top surface except for the above region,
The embossed pattern forms a bottom portion, a middle portion, and a top portion of the composite sheet material having different thicknesses,
There is no uneven pattern on the bottom,
The intermediate portion is approximately flat and/or approximately sloped, and an uneven pattern is formed in the intermediate portion,
The uneven pattern of the intermediate part is different from the pattern of the top part and/or the bottom part,
The total area of the convex portions of the uneven pattern in the intermediate portion is 25% to 75% of the total area of the intermediate portion,
A vehicle interior material, characterized in that the depth of the concave portions of the concavo-convex pattern is more than 1 mm, and the distance between adjacent concave portions of the concave-convex pattern is 0.1 mm or more in any one of vertical, horizontal, and diagonal directions. manufacturing method. The area of the recess in a part of the area including the end of the top surface of the embossing part is 25% to 75% of the area of the area,
The depth of the recess is more than 1 mm, and the distance between adjacent recesses is 0.1 mm or more in any of the vertical, horizontal, and diagonal directions,
The method for manufacturing a vehicle interior material according to claim 1, wherein the embossing portion has a height of 1 mm or more.

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